Electrode structure and the corresponding electrical component using the same and the fabrication method thereof

ABSTRACT

An electrical component is disclosed, wherein the electrical component comprises: a body; a conductive element disposed in the body, wherein at least one portion of a terminal part of the conductive element is exposed outside of the body; a metal foil having an adhesive material on the bottom surface thereof, the metal foil being adhered on the body through the adhesive material and covering a first portion of the terminal part of the conductive element, wherein a second portion of the terminal part of the conductive element is not covered by the metal foil; and a metal layer, overlaying on the metal foil and covering the second portion of the terminal part of the conductive element, wherein the metal layer is electrically connected to the second portion of the terminal part of the conductive element for electrically connecting with an external circuit.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/023,174 filed on Jul. 10, 2014, which is herebyincorporated by reference herein and made a part of specification.

BACKGROUND OF THE INVENTION

I. Field of the Invention

the present invention relates to an electrical component, and inparticularly, to the electrodes of the electrical component.

II. Description of the Prior Art

As an electrical component or an electronic device becomes smaller andsmaller, the size and the reliability of the electrode structure becomesa bottleneck considering the electrical performance and the reliabilityof the electrical component. The electrodes are used to connect theelectrical component to an external circuit such as a printed circuitboard (PCB), and terminals of the conductive elements of the electricalcomponent are electrically connected to corresponding electrodes such assurface-mount pads for soldering onto the corresponding pads on the PCB.A lead frame is usually welded to the terminals of the electricalcomponent; however, the size of the lead frame normally takes quite alarge space for an electrical component in a small foot print andtherefore, the lead frame is not suitable for being used as an electrodefor certain electrical components or electronic devices that requires asmaller size.

Surface Mount Technology (SMT) is a feasible way to reduce the overallsize of an electrical component or an electronic device, such as aresistor, a capacitor or an inductor. However, as the overall size ofthe electrical component becomes smaller and smaller, how to make thesurface-mount pads reliable in both mechanic and electrical aspects is avery important topic. The electrode created by conventionalelectroplating on an Ag glue layer which is susceptible to the changesof temperature or moisture, which degrades electrical performance andmechanical strength a lot in certain applications or even affect theyield rate of the electrical components in manufacturing factory. On theother hand, chemical plating can cause a short circuit when the materialof the plating spreads into certain unwanted areas.

Accordingly, the present invention proposes an electrode structure toovercome the above-mentioned problems.

SUMMARY OF THE INVENTION

One objective of the present invention is to provide an electrodestructure for connecting to an external circuit with improved electricalperformance and mechanical strength of the electrode structure.

In one embodiment, an electrical component is disclosed, the electricalcomponent comprising: a body; a conductive element disposed in the body,wherein at least one portion of a terminal part of the conductiveelement is exposed outside of the body; a metal foil having an adhesivematerial on the bottom surface thereof, the metal foil being adhered onthe body through the adhesive material and covering a first portion ofthe terminal part of the conductive element, wherein a second portion ofthe terminal part of the conductive element is not covered by the metalfoil; and a metal layer, overlaying on the metal foil and covering thesecond portion of the terminal part of the conductive element, whereinthe metal layer is electrically connected to the second portion of theterminal part of the conductive element for electrically connecting withan external circuit.

In one embodiment, the metal foil is a resin coated copper foil.

In one embodiment, the metal foil is made of Cu.

In one embodiment, the metal layer is made of Sn.

In one embodiment, the metal layer is made by electroplating.

In one embodiment, the metal foil is adhered on the first portion and athird portion of the terminal part of the conductive element, whereinthe second portion is located between the first portion and the thirdportion.

In one embodiment, a third portion of the terminal part of theconductive element is not covered by the metal foil, wherein the firstportion of the terminal part of the conductive element is locatedbetween the second portion and the third portion of the terminal part ofthe conductive element.

In one embodiment, a recess is formed on the top surface of the body,wherein the terminal part of the conductive element is disposed in therecess.

In one embodiment, the electrical component is an inductor and theconductive element is a coil, and the coil is disposed in the body withthe terminal part of the coil disposed in a recess on a surface of thebody.

In one embodiment, the electrical component is an inductor and theconductive element is a coil, wherein the body is a magnetic body andthe coil is disposed in the magnetic body with the terminal part of thecoil disposed in a recess on the bottom surface of the body, wherein themagnetic body comprises a T-core having a pillar, wherein the coilsurrounds the pillar and the terminal part of the coil disposed in therecess on the bottom surface of the magnetic body via a side surface ofthe T-core.

In one embodiment, an inductor is disclosed, the inductor comprising: amagnetic body; a coil, disposed in the magnetic body, wherein at leastone portion of a terminal part of the coil is exposed outside of themagnetic body; a metal foil, being adhered on the magnetic body andcovering a first portion of the terminal part of the coil, wherein asecond portion of the terminal part of the coil is not covered by themetal foil; and a metal layer, overlaying on the metal foil and coveringthe second portion of the terminal part of the coil, wherein the metallayer is electrically connected to the second portion of the terminalpart of the coil for electrically connecting with an external circuit.

In one embodiment, the magnetic body comprises a T-core having a pillar,wherein the coil surrounds the pillar and the terminal part of the coildisposed in a first recess on the bottom surface of the magnetic bodyvia a side surface of the T-core.

In one embodiment, a method to make an electrical component isdisclosed, the method comprising: proving a body, wherein a conductiveelement disposed in the body, wherein at least one portion of a firstterminal part of the conductive element is exposed outside of the body;and disposing a first metal layer on the body by using a PVD process,wherein the first metal layer covers the at least one portion of thefirst terminal part of the conductive element.

In one embodiment, in the method described above, at least one portionof a second terminal part of the conductive element is exposed outsideof the body, the method further comprising disposing a second metallayer on the body by using the PVD process, wherein the second metallayer covers the at least one portion of the second terminal part of theconductive element.

In one embodiment, in the method described above, the electricalcomponent is an inductor, wherein the body is a magnetic body and theconductive element is a coil, wherein the coil is disposed in themagnetic body with the terminal part of the coil disposed in a recess ona surface of the body.

In one embodiment, in the method described above, the electricalcomponent is an inductor, wherein the body is a magnetic body and theconductive element is a coil, wherein coil is disposed in the magneticbody with the terminal part of the coil disposed in a recess on thebottom surface of the body, wherein the magnetic body comprises a T-corehaving a pillar, wherein the coil surrounds the pillar and the terminalpart of the coil disposed in the recess on the bottom surface of themagnetic body via a side surface of the T-core.

In one embodiment, an electrical component is disclosed, the electricalcomponent comprising: a body; a conductor wire disposed in the body,wherein a first axial surface of a first end of the conductor wire and asecond axial surface of a second end of the conductor wire are exposedoutside of the body, wherein the first axial surface and the secondaxial surface are exposed on a same surface or two opposite surfaces ofthe body; a first electrode structure disposed on the body andelectrically connected to the first axial surface of the first end ofthe conductor wire; and a second electrode structure disposed on thebody and electrically connected to the second axial surface of thesecond end of the conductor wire.

In one embodiment, the electrical component further comprising aprotecting layer covering the outer surfaces of the body withoutcovering the first axial surface of the first end of the conductor wireand the second axial surface of the second end of the conductor wire.

In one embodiment, the electrical component is an inductor, wherein thebody is a magnetic body and the conductive wire is a coil, wherein thecoil is disposed in the magnetic body.

In one embodiment, the electrical component is an inductor and theconductive wire is a coil, wherein the body is a magnetic body and thecoil is disposed in the magnetic body with the terminal part of the coildisposed in a recess on the bottom surface of the body, wherein themagnetic body comprises a T-core having a pillar, wherein the coilsurrounds the pillar and the terminal part of the coil disposed in therecess on the bottom surface of the magnetic body via a side surface ofthe T-core.

The detailed technology and above preferred embodiments implemented forthe present invention are described in the following paragraphsaccompanying the appended drawings for people skilled in this field towell appreciate the features of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the accompanying advantages of thisinvention will become more readily appreciated as the same becomesbetter understood by reference to the following detailed descriptionwhen taken in conjunction with the accompanying drawings, wherein:

FIG. 1 illustrate an electrical component according to one embodiment ofthe present invention;

FIG. 2 illustrate a cross-sectional view of the II-II portion of FIG. 1in one embodiment;

FIG. 3 illustrates a cross-sectional view of the II-II portion of FIG. 1in another embodiment;

FIG. 4 illustrate a manufacturing process to make the electricalcomponent according to one embodiment of the present invention;

FIG. 5 illustrate a manufacturing process to make the electricalcomponent according to another embodiment of the present invention;

FIG. 6 illustrate a cross-sectional view of the electrical component ofFIG. 5 according to one embodiment of the present invention;

FIG. 7 illustrate a manufacturing process to make the electricalcomponent according to another embodiment of the present invention;

FIG. 8 illustrate a manufacturing process to make the electricalcomponent according to another embodiment of the present invention;

FIG. 9 illustrate a cross-sectional view of the electrical component ofFIG. 8 according to one embodiment of the present invention;

FIG. 10 illustrate a manufacturing process to make the electricalcomponent according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The detailed explanation of the present invention is described asfollowing. The described preferred embodiments are presented forpurposes of illustrations and description, and they are not intended tolimit the scope of the present invention.

Please refer to FIG. 1 and FIG. 2, which illustrates an electrodestructure of an electrical component according to an embodiment of thepresent invention. The electrode structure can be used to electricallyconnect terminals of conductive elements of the electrical componentwith an external circuit such as a printed circuit board (PCB). In oneembodiment, the electrical component comprises: a main body 10 and aconductive element 20 disposed in the main body 10, wherein theconductive element 20 has two terminal parts 21 a, 21 b and at least oneportion of each of the terminal part 21 a, 21 b is exposed outside ofthe main body 10; a metal foil 31 having an adhesive material 311 on thebottom surface thereof (please refer to FIG. 2), wherein the metal foil31 is adhered to the main body 10 through the adhesive material 311 andcovers a first portion 211 a and a third portion 213 a of the terminalpart 21 a, wherein a second portion 212 a of the terminal part 21 a ofthe conductive element are not overlaid by the metal foil 31; a firstmetal layer 32, overlaying on the metal foil 31 and the second portion212 a of the terminal part 21 a, wherein the first metal layer 32 iselectrically connected to the second portion 212 a of the terminal part21 a of the conductive element 20 to form a first electrode structurefor electrically connecting with an external circuit. Likewise, a secondelectrode structure that is the same as the first electrode structurecan be formed on the terminal part 21 b, which will not be describedfurther.

Please refer to FIG. 3, which illustrates a cross-sectional view of anelectrode structure of an electrical component according to anembodiment of the present invention, wherein the metal foil 31 isadhered to the main body 10 through the adhesive material 311 and coversthe first portion 211 a of the terminal part 21 a of the conductiveelement 20, wherein the second portion 212 a and a third portion 213 aof the terminal part 21 a of the conductive element 20 are not overlaidby the metal foil 31; a first metal layer 32, overlaying on the metalfoil 31 and the second portion 212 a and a third portion 213 a of theterminal part 21 a of the conductive element 20, wherein the first metallayer 32 is electrically connected to the second portion 212 a and thethird portion 213 a of the terminal part 21 a of the conductive element20 to form a first electrode structure for electrically connecting withan external circuit. Likewise, a second electrode structure that is thesame as the first electrode structure can be formed on the terminal part21 b, which will not be described further.

In one embodiment, the adhesive material 311 comprises polymer materialmixed with conductive material, such as Ag powder mixed with epoxyresin. The conductive material is not limited to the Ag powder, it canbe Cu powder or any other suitable conductive metal or alloy. In oneembodiment, the first metal layer comprises Sn. In one embodiment, theadhesive material 311 comprises resin or resin mixed with conductivematerial.

In one embodiment, the metal foil 31 is made of Cu. In one embodiment,the metal foil 31 is a Resin Coated Copper (RCC). That is, there can betwo conductive paths formed between the first metal layer 32 and theterminal parts 21 a, wherein a first conductive path is formed from theterminal parts 21 a to the first metal layer 32, and a second conductivepath is formed from the terminal parts 21 a to the first metal layer 32via the metal foil 31.

Please note that the shape of the metal foil 31 and the position of themetal foil 31 on the main body 10 relative to the terminal parts 21 a,21 b can be in any suitable pattern, not limited to the examples shownin FIG. 2 and FIG. 3.

In one embodiment, the first metal layer 32 overlays on the metal foil31 through a thick film process such as electroplating.

As shown in FIG. 1, the steps of manufacturing an inductor based on aT-core comprises: providing a T-core 11 having a pillar 12 (step S11);providing a conductive element 20 and winding the conductive element 20,such as a spiral coil, on the pillar 12 (step S12), wherein each of thetwo terminal parts 21 a, 21 b of the conductive element 20 is bent ontoa recess 112 on the top surface 111 of the T-core 11, wherein the shapeof the conductive element 20 can be round or flat wire; placing theconductive element 20 and the T-core 11 in a molding device, thenfilling magnetic powder material into the molding device, and thenapplying a hot pressing process on the magnetic powder materialencapsulating the conductive element 20 and the T-core 11 to form themagnetic body 10 (step S13); removing the insulating materialencapsulating the terminal parts 21 a, 21 b of the conductive element 20so as to expose the terminal parts 21 a, 21 b (step S14), wherein, forexample, the conductive element 20 is an enameled wire and theinsulating material of the enameled wire encapsulating the internalconductor can be removed by laser; adhering the metal foil 31 onto themagnetic body; and overlaying the first metal layer 32 on the metal foil31 and the second portion 212 a of the terminal part 21 a of theconductive element 20 for electrically connecting with an externalcircuit. In one embodiment, the first metal layer 32 can be Sn or Ni orany suitable metal or alloy. In one embodiment, the shape of theenameled wire can be round or flat or other suitable shape.

As shown in FIG. 4, the steps of manufacturing an inductor based on aT-core comprises: providing a T-core 11 having a pillar 12 (step S41);providing a conductive element 20 and winding the conductive element 20,such as a spiral coil, on the pillar 12 (step S42), wherein each of thetwo terminal parts 21 a, 21 b of the conductive element 20 is bent ontoa recess 131 on the bottom surface 13 of the magnetic body 10, whereinthe shape of the conductive element 20 can be round or flat wire;placing the conductive element 20 and the T-core 11 in a molding device,then filling magnetic powder material into the molding device, and thenapplying a hot pressing process on the magnetic powder materialencapsulating the conductive element 20 and the T-core 11 to form themagnetic body 10 (step S43); removing the insulating materialencapsulating the terminal parts 21 a, 21 b of the conductive element 20so as to expose the terminal parts 21 a, 21 b (step S44), wherein, forexample, the conductive element 20 is an enameled wire and theinsulating material of the enameled wire encapsulating the internalconductor can be removed by laser; performing a PVD (Physical VaporDeposition) process to form a metal layer 35 on the magnetic body 10 toencapsulate the terminal parts 21 a, 21 b (step S45). In one embodiment,the metal layer 35 can be Sn or Ni or any suitable metal or alloy. Inone embodiment, the shape of the enameled wire can be round or flat orother suitable shape.

Please refer to FIG. 5 and FIG. 6, which shows a structure of aninductor and the manufacturing process for making the inductor such as achoke. As shown in FIG. 5, the inductor or the choke comprises: a mainbody 10, a conductor wire 60, a protective layer 40 and an electrodestructure, wherein the conductor wires 60 is encapsulated in the mainbody 10 and the first axial surface 611 of the first end 61 of theconductor wire 60 and the second axial surface 621 of the second end 62of the conductor wire 60 are exposed outside of the main body 10 (seeFIG. 6), wherein a first electrode structure disposed on the main body10 and electrically connected with the first axial surface 611 of thefirst end 61 of the conductor wire 60, and a second electrode structuredisposed on the main body 10 and electrically connected with the secondaxial surface 621 of the second end 62 of the conductor wire 60. In oneembodiment, a protective layer 40 is disposed on the main body 10 tocover the outer surface of the main body 10, and then an outer portionof the protective layer 40 together with a first portion of the firstend 61 and a second portion of the second end 62 are removed to exposethe first axial surface 611 of the first end 61 of the conductor wire 60and the second axial surface 621 of the second end 62 of the conductorwire 60 outside the main body 10, wherein the first electrode structuredisposed on the main body 10 and electrically connected with the firstaxial surface 611 of the first end 61 of the conductor wire 60, and thesecond electrode structure disposed on the main body 10 and electricallyconnected with the second axial surface 621 of the second end 621 of theconductor wire 60. The aforementioned electrode structure can preventthe material of the electroplating spreads into certain unwanted areas.

In one embodiment, the electronic component in FIG. 5 an inductor,wherein the conductor wire 60 can be a spiral coil, but not limited to.In one embodiment, the electrode structure, as shown in FIG. 5,comprises: a first metal layer 33, a conductive adhesive 34 (e.g. silverpaste), and a second metal layer 36, wherein the first metal layer 33are attached and electrically connected with the first axial surface 611of the first end 61 of the conductor wire 60 and the second axialsurface 621 of the second end 62 of the conductor wire 60, theconductive adhesive 34 is disposed on the main body 10, and the secondmetal layer 36 is overlaid on the main body 10 to cover the conductiveadhesive layer 34 and a portion of the protective layer 40. In oneembodiment, the conductive adhesive layer 34 is overlaid on a portion orthe entire of the first metal layer 33; and in one embodiment, theconductive adhesive layer 34 is not overlaid on any portion of the firstmetal layer 33 at all. The purpose of the conductive adhesive 34 is toadhere the second metal layer 36 to the first metal layer 33 or theprotective layer 40 firmly.

In one embodiment, a method for manufacturing the inductor, as shown inFIG. 5, comprising: providing a conductor wire 60; forming a main body10 to encapsulate the conductor wire 60; forming a protective layer onthe outer surface of the main body 10; cutting off a first portion ofthe magnetic body along with a first portion of the first ending part ofthe wire conductor 60 to expose the first axial surface 611 of the firstend 61 of the wire conductor 60 and a second portion of the main body 10along with a second portion of the second ending part of the wireconductor 60 to expose the second axial surface 621 of the second end 62of the wire conductor 60; forming a first electrode structure on themain body 10 and electrically connected with the first axial surface 611of the first end 61 of the conductor wire 60 and a second electrodestructure on the main body 10 and electrically connected with the secondaxial surface 621 of the second end 62 of the conductor wire 60.

In one embodiment, the wire conductor 60 is a round or a flat wire, butnot limited to. In one embodiment, the first axial surface 611 of thefirst end 61 of the wire conductor 60 and the second axial surface 621of the second end 62 of the wire conductor 60 are located on a samesurface of the main body 10. In one embodiment, the first axial surface611 of the first end 61 of the wire conductor 60 and the second axialsurface 621 of the second end 62 of the wire conductor 60 are locatedtwo opposite surfaces of the main body 10, as shown in FIG. 6.

In one embodiment, a manufacturing process for manufacturing theinductor, as shown in FIG. 5, comprising the steps of: providing aconductor wire 60 and a lead frame 50, wherein each end of the conductorwire 60 is fixed by the lead frame (step S51), the conductor wire 60 canbe a spiral coil 60 that is made of enameled wire. The shape of the wirecan be round or flat or other suitable shape; placing the conductor wire60 and the lead frame 50 in a molding device, then filling magneticpowder material into the molding device, and then applying cold pressingprocess followed by hot pressing process on the magnetic powder materialencapsulating the conductor wire 60 and a portion of the lead frame 50to form the main body 10 such as an magnetic body (step S52); cuttingoff a portion of the main body 10 together with the lead frame andpolishing the outer surfaces of the main body 10 (step S53); coating aprotective layer 40 on the outer surfaces of the main body 10 (stepS54); removing off the lead frame together with a portion of the endingpart of the conductor wire 60 to expose the first axial surface 611 ofthe first ending part 61 of the wire conductor 60 and the second axialsurface 621 of the second ending part 62 of the wire conductor 60,wherein the cutting line is along the line L1, as shown in FIG. 6 (stepS55), wherein the ratio of the winding space of the coil relative to thesize of the magnetic body can be increased; forming a first electrodestructure on the main body 10 and electrically connected with the firstaxial surface 611 of the first end 61 of the conductor wire 60 and asecond electrode structure on the main body 10 and electricallyconnected with the second axial surface 621 of the second end 62 of theconductor wire 60 (step S55), wherein each of the electrode structurecomprises: a first metal layer 33, a conductive adhesive layer 34 (e.g.silver paste), and a second metal layer 36, wherein the first metallayer 33 are attached and electrically connected with the first axialsurface 611 of the first end 61 of the conductor wire 60 and the secondaxial surface 621 of the second end 62 of the conductor wire 60, theconductive adhesive layer 34 is disposed on the main body 10, and thesecond metal layer 36 is overlaid on the main body 10 to cover theconductive adhesive layer 34 and a portion of the protective layer 40.

In one embodiment, the conductive adhesive 34 is overlaid on a portionor the entire of the first metal layer 33; and in one embodiment, theconductive adhesive layer 34 is not overlaid on any portion of the firstmetal layer 33 at all. The purpose of the conductive adhesive layer 34is to adhere the second metal layer 36 to the first metal layer 33 orthe protective layer 40 firmly.

In one embodiment, the first metal layer 33 is made by electroplating orCVD or PVD process. In one embodiment, the first metal layer 33 is madeof Cu, Ag or other suitable metal or alloy. In one embodiment, thesecond metal layer 36 is made by electroplating process. In oneembodiment, the second metal layer 36 is made of Sn, Ni, or othersuitable metal or alloy.

Please refer to FIG. 7, which shows another manufacturing process formanufacturing the inductor. The steps of S51˜S55 are the same asdescribed above for FIG. 5 and the differences between the FIG. 7 andFIG. 5 lies in the electrode structure.

The electrode structure, as shown in S76 of the FIG. 7 comprises theconductive adhesive 34 and the second metal layer 36, wherein the secondmetal layer 36 overlays on the main body 10 to cover the conductiveadhesive layer 34 and a portion of the protective layer 40 andelectrically connects with the first axial surface 611 of the first end61 of the conductor wire 60 and the second axial surface 621 of thesecond end 62 of the conductor wire 60, respectively.

In one embodiment, the conductive adhesive layer 34 is adhered on theprotective layer 40 on the bottom surface of the main body 10 foradhering the second metal layer 36 to the protective layer 40 on thebottom surface of the main body 10. In one embodiment, the second metallayer 36 is in a shape of L (as shown in S56 of FIG. 5).

Please refer to FIG. 8 and FIG. 9, which shows another manufacturingprocess for manufacturing the inductor based on a T-core.

As shown in FIG. 8, the steps of manufacturing the inductor based on aT-core comprises: providing a T-core 11 having a pillar 12 (step S81);winding a conductive wire 60, such as a spiral coil on the pillar 12(step S82); bending each of the two terminal parts 61, 62 of theconductive wire 60 onto the bottom surface of the T-core 11 (step S83),wherein the shape of the conductive wire 60 can be round, flat, or othersuitable shape; placing the conductor wire 60 and the T-core 11 in amolding device, then filling magnetic powder material into the moldingdevice, and then applying a hot pressing process on the magnetic powdermaterial encapsulating the conductor wire 60 and the T-core 11 to formthe main body 10 (step S84), wherein each of the two terminal parts 61,62 of the conductive wire 60 is bent onto a recess 131 on the bottomsurface 13 of the main body 10; coating a protective layer 40 on theouter surfaces of the main body 10 (step S85); removing off a portion ofthe main body 10 together with a portion of the ending part of theconductor wire 60 to expose the first axial surface 611 of the firstending part 61 of the wire conductor 60 and the second axial surface 621of the second ending part 62 of the wire conductor 60, wherein thecutting line is along the line L2, as shown in FIG. 9 (step S86),wherein the ratio of the winding space of the coil relative to the sizeof the magnetic body can be increased; forming a first metal layer 33 byelectroplating or a PVD process (step S87), wherein be first metal layer33 can be made of Cu, Ag or other suitable metal or alloy; forming theconductive adhesive layer 34 such as Ag glue (step S88); forming asecond metal layer 36 by electroplating process (step S89).

Please refer to FIG. 10 which shows another manufacturing process formanufacturing the inductor, wherein the steps of S81˜S86 are the same asdescribed above for FIG. 8 and the differences between the FIG. 8 andFIG. 10 lies in the electrode structure.

The electrode structure in FIG. 10 is the same as the electrodestructure shown in S76 of the FIG. 7, wherein the electrode structurecomprises the conductive adhesive layer 34 and the second metal layer36, wherein the second metal layer 36 overlays on the main body 10 tocover the conductive adhesive layer 34 and a portion of the protectivelayer 40 and electrically connects with the first axial surface 611 ofthe first end 61 of the conductor wire 60 and the second axial surface621 of the second end 62 of the conductor wire 60, respectively. Thesteps S98 and S99 in FIG. 10 are described as following: forming theconductive adhesive layer 34 such as Ag glue (step S98); and forming asecond metal layer 36 by electroplating process (step S99).

In one embodiment, the length of the pillar of the T-core is relativelyshort for better shielding and high density for increasing thepermeability of the choke. The coil can be formed by enameled wire, andthe insulating material of the enameled wire encapsulating the internalconductor can be removed by laser. The shape of the enameled wire can beround or flat or other suitable shape. However, the DCR of the flat wireis less than that of the round wire. In one embodiment, the round orflat wire can surround the pillar of the T-core by a machineautomatically.

The electrodes of this invention are formed without having a lead framein the final product, so that the choke can be made smaller and thinner.

Furthermore, the terminal parts of the coil are placed outside of theareas for winding the coil to increase the winding space. The terminalparts of the coil can be embedded in a recess on the top surface of themagnetic body. In addition, the T-core can have recesses on the cornersfor passing the terminal parts, so that the terminal parts of the coilcan be fixed firmly. By doing so, there is no soldering required insidethe magnetic body for connecting the terminal parts of the coil of thechoke to the outside electrodes at all.

The above disclosure is related to the detailed technical contents andinventive features thereof. People skilled in this field may proceedwith a variety of modifications and replacements based on thedisclosures and suggestions of the invention as described withoutdeparting from the characteristics thereof. Nevertheless, although suchmodifications and replacements are not fully disclosed in the abovedescriptions, they have substantially been covered in the followingclaims as appended.

What is claimed is:
 1. An electrical component, comprising: a body; aconductive element disposed in the body, wherein at least one portion ofa terminal part of the conductive element is exposed outside of thebody; a metal foil having an adhesive material on the bottom surfacethereof, the metal foil being adhered on the body through the adhesivematerial and covering a first portion of the terminal part of theconductive element, wherein a second portion of the terminal part of theconductive element is not covered by the metal foil; and a metal layer,overlaying on the metal foil and covering the second portion of theterminal part of the conductive element, wherein the metal layer iselectrically connected to the second portion of the terminal part of theconductive element for electrically connecting with an external circuit.2. The electrical component according to claim 1, wherein the electricalcomponent is an inductor or a choke, wherein the body is a magnetic bodyand the conductive element is a conductive wire.
 3. The electricalcomponent according to claim 1, wherein the metal foil is coated withconductive adhesive material on the bottom surface thereof.
 4. Theelectrical component according to claim 1, wherein the metal foil is aresin coated copper foil.
 5. The electrical component according to claim1, wherein the metal foil is made of Cu.
 6. The electrical componentaccording to claim 1, wherein the metal layer is made of Sn or Ni. 7.The electrical component according to claim 1, wherein the metal layeris made by electroplating.
 8. The electrical component according toclaim 1, wherein the metal foil is adhered on the first portion and athird portion of the terminal part of the conductive element, whereinthe second portion is located between the first portion and the thirdportion.
 9. The electrical component according to claim 1, wherein athird portion of the terminal part of the conductive element is notcovered by the metal foil, wherein the first portion of the terminalpart of the conductive element is located between the second portion andthe third portion of the terminal part of the conductive element. 10.The electrical component according to claim 1, wherein a recess isformed on the top surface of the body, wherein the terminal part of theconductive element is disposed in the recess.
 11. The electricalcomponent according to claim 1, wherein the electrical component is aninductor and the conductive element is a coil, and the coil is disposedin the body with the terminal part of the coil disposed in a recess on asurface of the body.
 12. The electrical component according to claim 1,wherein the electrical component is an inductor and the conductiveelement is a coil, wherein the body is a magnetic body and the coil isdisposed in the magnetic body with the terminal part of the coildisposed in a recess on the bottom surface of the body, wherein themagnetic body comprises a T-core having a pillar, wherein the coilsurrounds the pillar and the terminal part of the coil disposed in therecess on the bottom surface of the magnetic body via a side surface ofthe T-core.
 13. A method to make an electrical component, comprising:proving a body, wherein a conductive element disposed in the body,wherein at least one portion of a first terminal part of the conductiveelement is exposed outside of the body; and disposing a first metallayer on the body by using a PVD process, wherein the first metal layercovers the at least one portion of the first terminal part of theconductive element.
 14. The method according to claim 13, wherein atleast one portion of a second terminal part of the conductive element isexposed outside of the body, the method further comprising disposing asecond metal layer on the body by using the PVD process, wherein thesecond metal layer covers the at least one portion of the secondterminal part of the conductive element.
 15. The method according toclaim 13, wherein the electrical component is an inductor, wherein thebody is a magnetic body and the conductive element is a coil, whereinthe coil is disposed in the magnetic body with the terminal part of thecoil disposed in a recess on a surface of the body.
 16. The methodaccording to claim 13, wherein the electrical component is an inductor,wherein the body is a magnetic body and the conductive element is acoil, wherein coil is disposed in the magnetic body with the terminalpart of the coil disposed in a recess on the bottom surface of the body,wherein the magnetic body comprises a T-core having a pillar, whereinthe coil surrounds the pillar and the terminal part of the coil disposedin the recess on the bottom surface of the magnetic body via a sidesurface of the T-core.
 17. An electrical component, comprising: a body;a conductor wire disposed in the body, wherein a first axial surface ofa first end of the conductor wire and a second axial surface of a secondend of the conductor wire are exposed outside of the body, wherein thefirst axial surface and the second axial surface are exposed on a samesurface or two opposite surfaces of the body; a first electrodestructure disposed on the body and electrically connected to the firstaxial surface of the first end of the conductor wire; and a secondelectrode structure disposed on the body and electrically connected tothe second axial surface of the second end of the conductor wire. 18.The electrical component according to claim 17, further comprising aprotecting layer covering the outer surfaces of the body withoutcovering the first axial surface of the first end of the conductor wireand the second axial surface of the second end of the conductor wire.19. The electrical component according to claim 17, wherein theelectrical component is an inductor, wherein the body is a magnetic bodyand the conductive wire is a coil, wherein the coil is disposed in themagnetic body.
 20. The electrical component according to claim 17,wherein the electrical component is an inductor and the conductive wireis a coil, wherein the body is a magnetic body and the coil is disposedin the magnetic body with the terminal part of the coil disposed in arecess on the bottom surface of the body, wherein the magnetic bodycomprises a T-core having a pillar, wherein the coil surrounds thepillar and the terminal part of the coil disposed in the recess on thebottom surface of the magnetic body via a side surface of the T-core.